NORMALAB NDI 450 Maintenance Manual

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NORMALAB France

MAINTENANCE NOTICE

NDI 450

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1 CONTENTS

1 CONTENTS 2

2 STRUCTURE OF THE MACHINE 6

2.1 MECHANICAL STRUCTURE 6

2.1.1 HEATING BLOCK 6

2.1.2 SUBSET COMPARTMENT 6

2.1.3 SUBSET CONDENSER 7

2.1.4 THE VENTILATION 7

2.2 ENVIRONNEMENT OF THE MACHINE 8

2.3 ELECTRONIC STRUCTURE 9

2.3.1 ELECTRONIC STRUCTURE 9

2.3.2 LOCATION OF THE ELECTRONIC BOARDS 9

2.3.3 THE EXTERNAL CONNECTIONS 11

3 INSTRUCTION SHEETS 12

3.1 ACCESS TO PARTS OF THE MACHINE 12

3.1.1 OPENING THE PANELS 12

3.1.2 REMOVING THE FRONT PANEL 13

3.1.3 ACCESS TO THE ELECTRONIC DRAWER 15

3.2 LEVEL FOLLOWER 16

3.2.1 REPLACEMENT OF THE 1RST DROP OPTICAL SENSOR 16

3.2.2 REPLACEMENT OF THE FOLLOWER OPTICAL SENSOR 17

3.2.3 REPLACEMENT OF THE LIMIT SWITCHES OF FOLLOWER 18

3.2.4 REPLACEMENT OF DRIP DEFLECTOR DETECTOR 19

3.2.5 REPLACEMENT OF STEP BY STEP MOTOR 22

3.2.6 REPLACEMENT OF THE MOTOR BOARD 24

3.2.7 REPLACEMENT OF DETECTOR OR MAGNET OF COMPARTMENT DOOR 25

3.3 HEATING BLOCK 26

3.3.1 REPLACEMENT OF THE HEATING ELEMENT 26

3.3.2 REPLACEMENT OF TURBINE 27

3.3.3 REPLACEMENT OF FIRE DETECTION THERMOCOUPLE 28

3.3.4 REPLACEMENT OF VAPOR PROBE’S DETECTOR 29

3.3.5 REPLACEMENT THE MECHANICAL SYSTEM OF SAMPLE PROBE DETECTION 30

3.3.6 REPLACEMENT OF HEATING BLOCK DOOR’S DETECTOR 30

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3.4 CONDENSER 31

3.4.1 REPLACEMENT CONDENSER PROBE 31

3.5 COOLING CONDENSER SYSTEM 32

3.5.1 REPLACEMENT OR DRAIN OF THE COOLANT LIQUID CIRCUIT 32

3.5.2 REPLACEMENT OF PUMP 32

3.5.3 REPLACEMENT OF FILTER OR FAN 35

3.5.4 REPLACEMENT OF FAN 36

3.5.5 REPLACEMENT OF FAN SPEED THERMOSTAT 36

3.5.6 REPLACEMENT OF PELTIER SUBSET 37

3.5.7 ADJUSTMENT OR REPLACEMENT OF THE LIQUID LEVEL DETECTOR 40

3.5.8 REPLACEMENT OF SUBSET PELTIER POWER SUPPLY 41

3.6 COMPARTMENT COOLING SYSTEM 42

3.6.1 REPLACEMENT OF THE FILTERS OR FANS 42

3.6.2 REPLACEMENT OF THE PELTIER SUBSET OF RECEIVER COMPARTMENT 43

3.6.3 REPLACEMENT OF THE COMPARTMENT PROBE 46

3.6.4 REPLACEMENT OF SUBSET PELTIER POWER SUPPLY 47

3.7 CHASSIS 47

3.7.1 REPLACEMENT OF THE HEATING TRANSFORMER 47

3.7.2 REPLACEMENT OF THE HEATING FUSE 48

3.7.3 REPLACEMENT OF THE CIRCUIT BREAKER 49

3.7.4 REPLACEMENT OF THE CL3 BOARD 50

3.7.5 REPLACEMENT OF THE AMBIENT PROBE 51

3.8 ELECTRONIC DRAWER 51

3.8.1 REPLACEMENT OF THE CL1 BOARD 51

3.8.2 THE BAROMETRIC SENSOR 52

3.8.3 REPLACEMENT PROCESS OF THE MICROPROCESSOR BOARD 53

3.8.4 REPLACEMENT OF THE POWER SUPPLY OF UC BOARD OR STEP BY STEP MOTOR 53

3.9 FRONT PANEL 54

3.9.1 REPLACEMENT OF MMI MICROPROCESSOR BOARD 54

3.9.2 REPLACEMENT OF THE HARD DRIVE DISK 54

3.9.3 REPLACEMENT OF THE LCD DISPLAY 55

3.9.4 REPLACEMENT OF INVERTER BACKLIGHT 56

3.9.5 REPLACE THE TOUCH SCREEN CONTROLLER 56

4 CALIBRATION AND MAINTENANCE FUNCTIONS 57

4.1 CALIBRATION FUNCTIONS 57

4.2 OPTIONS AND EQUIPMENT REQUIRED 59

4.3 CALIBRATION OF SAMPLE TEMPERATURES 59

4.3.1 EXAMPLE OF CREATION OF A NEW CALIBRATION 60

4.3.2 COMMISSIONING A NEW SAMPLE TEMPERATURE PROBE 64

4.4 THE PT 100 TEMPERATURE PROBES INTERNAL TO THE INSTRUMENT 64

4.5 TEMPERATURE MEASUREMENTS BY THERMOCOUPLE 65

4.6 CALIBRATION OF THE BAROMETRIC SENSOR 65

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4.7 CALIBRATION OF TEST TUBES 67

4.8 CALIBRATION OF THE TACTILE PAD 68

4.9 MONITORING EXPIRY OF CALIBRATION DEADLINES 68

5 DENOMINATION AND FUNCTIONS OF THE ELECTRONIC BOARDS 69

5.1 PROCESS CPU 69

5.2 MMI CPU 69

5.3 CL1 BOARD : 69

5.4 CL2 BOARD : 70

5.5 CL3 BOARD : 70

5.6 CL4 BOARD : 70

5.7 CL56F ET CL 56C BOARDS : 70

5.8 STEPPER BOARD: 71

6 SCHEMATIC ELECTRICAL AND ELECTRONIC 71

6.1 INTERCONNECTION SCHEME 71

6.2 SPARES PART LIST 73

6.2.1 PROBES AND THERMOCOUPLES 73

6.2.2 FIRST DROP AND FOLLOWER OPTICAL SENSORS 73

6.3 SCHEME OF ELECTRONIC BOARDS 74

6.3.1 CL1 BOARD 74

6.3.2 CL2 BOARD 76

6.3.3 CL3 BOARD 77

6.3.4 CL4 BOARD 78

6.3.5 CL56 BOARD 79

6.3.6 STEPPER MOTOR BOARD 80

6.3.7 DETECTOR PROBE AND DOOR CLOSED DETECTOR SENSOR 80

6.3.8 FRONT PANEL 81

7 SPARES PART LIST 83

8 TROUBLES SHOOTING 93

9 ANNEXE 1 97

9.1 GUIDE TO UPDATE INSTRUMENT 97

9.2 SAFETY RULES 97

9.3 GENERAL CHARACTERISTICS 97

9.4 CONTENT OF NEW VERSION 97

9.5 HOW TO GET A NEW VERSION 97

9.6 HOW TO KNOW THE SOFTWARE VERSION 98

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9.7 IMPORTANT RECOMMENDATIONS 98

9.8 ADDITIONAL REQUIREMENTS TO UPDATE YOUR NDI450 INSTRUMENT 98

9.9 PREPARE YOUR USB FLASH DRIVE FOR UPDATING (VIDEO EXAMPLE) 98

9.10 INSTALL A NEW MMI VERSION USING THE UPDATE OPTION (VIDEO EXAMPLE) 100

9.11 INSTALL A NEW FIRMWARE VERSION USING THE UPDATE OPTION (VIDEO EXAMPLE) 103

9.12 ERROR MESSAGES 106

10 ANNEXE 2 107

10.1 LOGBOOK 107

11 ALARM LIST 111

12 NOTES : 117

Version 04-2012

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2 Structure of the machine

2.1 Mechanical structure

2.1.1 Heating block

2.1.2 Subset compartment

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2.1.3 Subset condenser

2.1.4 The ventilation

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2.2 Environnement of the machine

The machine must be installed on the stable bench , can supported the weight of the apparatus ( see
characteristics)

It is necessary to respect a minimum environment volume to ensure proper operation and longevity
.

Allow minimum space : 25cm behind and 40 cm on the sides , 100 cm above to ensure adequate
ventilation space.

Do not install the machine near the heating source ( radiator , stove , oven or apparatusl sending hot
air , …), or behing a window receiving the sun

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2.3 Electronic structure

2.3.1 Electronic structure

2.3.2 Location of the electronic boards

CL3

board

CL2 board and

Stepper motor

board

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CL56F
board

CL56C
board

Inverter pour

backlight

CL56F
board

MMI CPU

board

Touch screen’s

driver

Hard
drive disk

Inverter pour

backlight

CL56F
board

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2.3.3 The external connections

2.3.3.1 Keyboard, mouse, printer, monitor, network

Devices type

Port

Video monitor

VGA port on the back side

Keyboard

USB Port on the left side and back side

Printer

USB Port on the left side and back side

Network

Port RJ 45 on the back side

Serial port

Com port on the back side ( 9 pins SubD)

USB key for exportation files

USB Port on the left side and back side

USB key for process restoration

Update port USB

USB Key for MMI or standard update

USB Port on the left side and back side

Power supply

for CPU

Power supply for

stepper motor

CL4 Board

CL1 Board

CPU Process

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3 Instruction sheets

3.1 Access to parts of the machine

3.1.1 Opening the panels

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3.1.2 Removing the front panel

Remove the side and rear panels (see
above procedure 3.1.1)

Remove the compartment door : remove the 4
hinge screws

Remove the 2 drawers :

- Condensates drawer of compartment

- Drawer under heating block

Remove the cap of the expansion tank
Remove the 2 screws

Remove the upper panel

Tools

1 hex head key 2 mm
1 hex head key 2.5 mm
1 hex head key 3 mm

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Remove the holding screw on the left side

Remove the 5 screw of the front panel

Remove this holding screw

Remove the 2 black knobs fixing the electronic
drawer

Pull slightly the panel forward

Unplug the ribbon of front panel

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Unplug the network cable ( RJ45)

The front panel is free , you can remove it

3.1.3 Access to the electronic drawer

Remove the 2 screws of the upper left panel and
lift the panel on the back
Remove the ground wire

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3.2 Level follower

3.2.1 Replacement of the 1rst drop optical sensor

Remove the holding screw

Pull out the optical sensor from the slide
Remove the Jack connector

Plug the connector on the new optical sensor
(Pay attention at the cable to not hinder the
movement of the follower)
Replace the new optical sensor in the slide
Tighten the holding screw
Loosen the locking screw to adjust the optical
position with the adjusting screw

Place a 4mm Ø screwdriver in vertical position
and aligned with the condenser

Read the good position on the maintenance screen
( adjust slowly because the refreshment is slow)

Locking

screw

Holding

screw

Adjusting

screw

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3.2.2 Replacement of the follower optical sensor

With the
maintenance
functions ,to do
raise the follower
sensor of 5 cm to
release it from the
follower base
Proceed the same
way as first drop
sensor to remove
the optical sensor

Loosen the
blocking screw and
adjust the optical
sensor position
with the adjusting
screw

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3.2.3 Replacement of the limit switches of follower

Tools

1 hex head key 4 mm
1 tubular key 5.5 mm
1 flat blade screwdriver 3.5m

Remove the right panel (see the above procedure 3.1.1)

Position of the low and high sensors

Loosen the maintaining nut of sensor

Release the wires

Extract the sensor ( identify the sense of the
position to replace the new one in the same
sense)

Disconnect the wires from connector of
CL2 board
Low sensor :

- Red 1

- Blue 2

- Black 3

High sensor

- Red 4

- Blue 5

- Black 6

1

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3.2.4 Replacement of drip deflector detector

Tools

1 hex head key 3 mm
1 wrench 7mm

Remove the front panel (see above procedure 3.1.1)

Remove the roof of the receiver
compartment(2 hex screws)and extract it
(take care at the heating insulation)

Remove the flange around the condenser
Remove the optical sensor ( without
modifying the position adjustment)

Unplug the optical sensor cable

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Remove the 2 maintaining scews

Remove the compartment probe

Lift the probe above condenser

Release the wires and turn the holder around the
condenser ( lift slightly the condenser tube)

Place the holder in front of condenser tube
to access by above

Loosen the maintaining screw

Vis de

maintien

capteur

Capteur

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Remove completely the screw and close the
hole to maintain the spring

Once the screws to release the spring, the sensor can
be extracted (mark the direction of the sensor)

Place the new sensor in the holder(the target
must be to the drip deflector)

Replace the medium in the slide, put the spring, push
the spring so that the screw can pass

Tighten the screw taking care the spring is
below

Check the mechanical operation with your drip
deflector

Unplug the old sensor

Connect the wires of the new one :

- Brown 7 of J3

- Black 8 of J3

- Blue 9 of J3

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3.2.5 Replacement of step by step motor

Tools

1 hex head key 2.5 mm
1 hex head key 2 mm
1 hex head key 1.5 mm
1 hex head key 4 mm

Remove the follower optical sensor (see above procedure 3.2.2)

Release the wires

Remove the 5 side screws on the left under the
insulation

Remove the 4 side screws on the right under the
insulation

Unplug the pilot wires of motor on the motor
board and the sensors on the CL2 board

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Return the guide assembly

Loosen the motor coupling

Remove the motor

At the reassembling , replace correctly the
insulation

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3.2.6 Replacement of the motor board

Tools

1 hex head key 2 mm
1 tube wrench 5.5 mm
Remove the CL2 board with the 4 screws

Remove the connector of the motor board

Remove the motor board

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3.2.7 Replacement of detector or magnet of compartment door

Tools

1 hex head key 2 mm

Remove the front panel of the apparatus (see above procedure 3.1.2)

Remove the sensor

- Red wire on 7 of J1

- Blue wire on 8 of J1

- Black wire on 9 of J1

Identify the position of the sensor

The magnet which activates the sensor

The magnet must present a south pole ( it
attracts the North of the compass needle)

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3.3 Heating block

3.3.1 Replacement of the heating element

Tools

1 cutting pliers

Apparatus power off , and cold heating element

Pull verticaly the heating assembly

Carefully pry the heating element

Access to the connectors of heating element and
thermocouple

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Plug the new element ( heating and
thermocouple)

Replace by clipping the element

3.3.2 Replacement of turbine

Tools

1 tube wrench 7 mm
1 soldering iron
welding

Remove the 3 fixing screws
Follow the wires in the raceway to remake the
splices

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3.3.3 Replacement of fire detection thermocouple

Tools

Cutting pliers

Remove the front panel (see above procedure 3.1.2)

Position of thermocouple

Cut the collar , unplug the thermocouple

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3.3.4 Replacement of vapor probe’s detector

Remove the left upper panel (see above procedure3.1.2)

Position of the sensor

Remove the circuit breaker holder

Remove the circuit breaker holder

Remove the fixing screws of sensor board and

release the ribbon

Tools

1 hex head key 2.5 mm

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3.3.5 Replacement the mechanical system of sample probe detection

Remove the left upper panel (see above procedure 3.1.1)

Tools

1 hex head key 2.5 mm

Remove the fixing screw

Take care at spring

3.3.6 Replacement of heating block door’s detector

Remove the front panel (see above procedure 3.1.2)

Tools

1 hex head key 2.5 mm

Position of the sensor

Remove the ribbon and the sensor

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3.4 Condenser

3.4.1 Replacement condenser probe

Tools

1 hex head key 3 mm
1 wrench 7 mm

Remove the front panel (see above procedure 3.1.2)

Remove the roof of the compartment (2 screws)
and extract it ( take care at the insulation )

Loosen the 2 screws of the flange and deposit it
Cut the fixing collar probe

Extract the probe of the housing

Unplug the probe wires from CL2 board.
Connector J3 on 14/15 and 16/17

Do not forget to replace the new fixing collar to
lock the probe in housing

A checking of the calibration may be necessary (by simulation of probe)

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3.5 Cooling condenser system

3.5.1 Replacement or drain of the coolant liquid circuit

Remove the right and rear panels (see above procedure 3.1.1)

Open the cap of the expansion tank

Open the valve to drain

Note: The liquid volume to fill circuit is approximately 250 mL

3.5.2 Replacement of pump

Tools

1 hex head key 3 mm
1 wrench 7 mm

Remove the left and rear panels (see above procedure 3.1.1)

Drain the liquid circuit (see above procedure 3.5.1)

2 assembly types

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Position of the pump

Remove the 2 fixing screws

Or remove the 4 nuts and lift the assembly and

rotate it

And remove the 2 fixing screws of the pump

Remove insulation fitting and disconnect them

Remove the frame fixations

1

2

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Remove the ribbons of CL3 board

Release the power supply frame on the left

Unplug the wires of the board

White wire in 1 and black wire on 2 of J10

At the reassembling ,properly position the frame

to match with amount of the frame

Beware the proper positioning of the bundle in

the notch

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3.5.3 Replacement of filter or fan

Remove the side and rear panels (see above procedure 3.1.1)

Push down with blade of the screwdriver

To unclip the filter holder

Clean or replace the filter

Replace the filter holder with filter

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3.5.4 Replacement of fan

Remove the left panel (see above procedure 3.1.1)

Remove the filter holder (see above procedure 3.5.3)

Tools

1 screwdriver 3 mm
1 tube key 7 mm

Remove the 4 fixing nuts

Remove the power supply wires

3.5.5 Replacement of fan speed thermostat

Remove the side and rear panels (see procedure 3.1.1)

Tools

1 hex head key 2.5 mm

Remove the 2 lugs

Remove the thermostat

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3.5.6 Replacement of Peltier subset

Remove the front panel (see above procedure 3.1.2)

Drain the liquid circuit (see above procedure 3.5.1)

Tools

1 wrench 10 mm
1 hex head key 3 mm
1 hex head key 2.5 mm

Remove the 4 fixing nuts

Unplug the low fitting of condenser

Unplug the high fitting of condenser

Remove the expansion tank

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Remove the level detector ( 3 screws)

Remove the tank

Raise the assembly to release the 4 studs

Release the assembly to unplug the pilot wires

Unplug the pilot wires : orange , red , green and

yellow

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Unplug the power supply wires

Extract the assembly

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3.5.7 Adjustment or replacement of the liquid level detector

Tools

1 hex head key 2.5 mm
1 screwdriver 1.5 mm

Remove the side and rear panels (see above procedure 3.1.1)

Remove the 3 fixing screws of sensor
Remove the wires on J7 of CL3 Board

Wires connections :

- Brown 5 on J7 CL3

- Black 6 on J7 de CL3

- Blue 7 on J7 de CL3

Low level detection

Sensitivity adjustment

Turn the sensitivity screw to switch on the lamp
and go back just before extinction

1°) Find the threshold point to switch on and
extinction lamp

2°) Repeat the operation and stop adjustment
just before extinction point

Power
supply lamp

Detection

lamp

Switch on
point

Extinction

point

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3.5.8 Replacement of subset Peltier power supply

Remove the right and rear panel (see above procedure 3.1.1)

Tools

1 cross tip screwdriver

Unplug the power supply wires

Unplug the main supply wires

Remove the 2 screws

Remove the power supply

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3.6 Compartment cooling system

3.6.1 Replacement of the filters or fans

Remove the right and rear panel (see above procedure 3.1.1)

Tools

1 screwdriver 3.5 mm

Position of filters and fans

Pull the filter holder to unclip

Release the filter in fiber

Clean or replace it

Replace the filter and his holder

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3.6.2 Replacement of the Peltier subset of receiver compartment

Tools

1 screwdriver 2.5 mm
1 iron solder
1 cutting plier
1 wrench 7 mm
1 wrench 10 mm

Remove the side and rear panels (see above procedure 3.1.1)

Remove the front panel (see above procedure 3.1.2)

Unplug the power supply wires

Remove the connectors from CL2 board and

motor board

Unplug the pilot wire and de-soldering the black

wire

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Unplug the 2 ribbons of CL3 board

Remove the roof of the compartment

Extract the roof

Remove the flange of condenser

Remove the condenser fixing in the heating

block part of condenser ( 3 screws)

Remove the first drop optical sensor

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Remove the centering condenser in

compartment

Remove the 4 fixing screws of subset

Release the centering condenser

Extract the subset by forward rotation

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3.6.3 Replacement of the compartment probe

Tools

1 hex head key 2.5 mm

Remove the side and rear panels (see above procedure 3.1.1)
Remove the front panel (see above procedure 3.1.2)

Remove the first drop sensor ( without
modifying the adjustment) see procedure 3.2.1)

Unplug the sensor
Remove the flange of the probe

Recover the probe ring to place it in the new one
( at 50 mm from the probe tip)

The wires are on 13-14 and 15-16 of J1
connector

The check of calibration may be necessary

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3.6.4 Replacement of subset Peltier power supply

See above procedure 3.5.8

3.7 Chassis

3.7.1 Replacement of the heating transformer

Tools

1 screwdriver 3.5 mm
1 hex head key 5.5 mm
1 hex head key 5 mm
1 wrench 12 mm

Remove the side and rear panels (see above procedure 3.1.1)

Remove the fixing screws of power supply frame

Remove the 2 ribbons of CL3 board

Release by rotation the supply frame

Unplug the transformer and remove it

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Coupling transformer

3.7.2 Replacement of the heating fuse

Remove the side and rear panel (see above procedure 3.1.1)

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3.7.3 Replacement of the circuit breaker

Tools

1 screwdriver 2.5 mm
1 iron solder
1 cutting pliers
1 wrench 7 mm
1 wrench 10 mm

Remove the left upper panel (see above procedure 3.1.3)

Remove the circuit breaker holder

Unplug the wires and remove the circuit breaker

by pulling the tab

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3.7.4 Replacement of the CL3 board

Remove the side and rear panels (see above procedure 3.1.1)

Tools

1 hex head key 5.5 mm
1 tube key 5.5 mm
1 wrench 12 mm

Remove the fixing supply frame

Remove the 2 ribbons of CL3 board

Unplug the wires of the board

Remove the 4 fixing nuts of the board

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3.7.5 Replacement of the ambient probe

Remove the side and rear panels (see above procedure 3.1.1)

Tools

1 hex head key 2.5 mm
1 tube key 5.5 mm

The probe is fixed with 2 collars

Unplug the wires on 10-11 and 12-13 of J3

The check of calibration may be necessary

3.8 Electronic drawer

3.8.1 Replacement of the CL1 board

Remove the left upper panel (see above procedure 3.1.3)

Tools

1 hex head key 4 mm
1 tube key 5.5 mm
1 screwdriver 3.5 mm

Remove the connections and disconnect the

pressure sensor

Remove the CPU

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3.8.2 The barometric sensor

Remove the left upper panel (see above procedure 3.1.3)

Tools

1 hex head key 4 mm
1 tube key 5.5 mm
1 screwdriver 3.5 mm

Remove the connections and disconnect the

pressure sensor

The barometric sensor is welded on SMD , see
procedure for removing CL1 board

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3.8.3 Replacement process of the microprocessor board

Tools

1 hex head key 2.5 mm
1 tube key 5.5 mm

Remove the left upper panel (see above procedure 3.1.3

The CPU is mounted in mezzanine on the CL1

board

The new CPU must be preloaded with the NDI

process version

3.8.4 Replacement of the power supply of UC board or step by step motor

Remove the left upper panel (see above procedure 3.1.3

Tools

1 hex head key 2.5 mm
1 iron soldering and
welding

De-soldering power supply wires and the power

supply output

Put the new power supply and check the 5V on

the CPU terminal. For stepper motor board , it is

better to adjust the voltage at 5.2 V

CPU power

supply

Stepper motor power

supply

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3.9 Front panel

3.9.1 Replacement of MMI microprocessor board

Remove the side and rear panels (see above procedure 3.1.1)
Remove the front panel (see above procedure 3.1.2)

Tools

1 screwdriver 2.5 mm
1 tube key 5.5 mm

Remove the connections and remove the CPU

3.9.2 Replacement of the hard drive disk

Remove the side and rear panels (see above procedure 3.1.1)
Remove the front panel (see above procedure 3.1.2)

Tools

1 screwdriver 2.5 mm
1 tube key 5.5 mm

Remove the connections and remove the hard

drive disk

Take care at the red mark of the ribbon and the

pin out of hard drive disk connector

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3.9.3 Replacement of the LCD display

Remove the side and rear panels (see above procedure 3.1.1)

Remove the front panel (see above procedure 3.1.2)

Tools

1 hex head key 2.5 mm

Remove the 2 fixing screws

Release the cable

Extract the LCD subset

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3.9.4 Replacement of inverter backlight

Remove the side and rear panels (see above procedure 3.1.1)

Remove the front panel (see above procedure 3.1.2)

Tools

1 screwdriver 2.5 mm
1 tube key 5.5 mm

Remove the connection and remove the inverter

3.9.5 Replace the touch screen controller

Remove the side and rear panels (see above procedure 3.1.1)

Remove the front panel (see above procedure 3.1.2)

Tools

1 screwdriver 2.5 mm
1 tube key 5.5 mm

Remove the connection and remove the

controller

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4 CALIBRATION AND MAINTENANCE FUNCTIONS

4.1 Calibration functions

Enter the password.

NB: on delivery of the instrument, the password is 0000.

There are 3 options for calibrating the instrument:

- Calibrating the complete measuring system (probe and electronics)

- Simulating the probe using a decade resistor or a calibrator (this method allows

calibrating exclusively the electronics, the probe error is thus not taken into account).

- Calibration by point (which allows entering the former calibration values to replace any

missing or erroneous values).

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Calibration of the complete system is the most accurate system since it incorporates the probe error
in the calibration to offset it. As a result, the probe must be mobile and two calibration baths
stabilised at precisely known temperatures are required. This method is reserved for the sample
probe (the other probes internal to the instrument are not mobile and their calibration does not
require such accuracy).

Calibration using two points adjusts the high point and the low point and defines a line interpolated
between them. Each reading above and below the calibration points will be an extension of the
interpolation line. For this reason, it is preferable to calibrate with two points as far away as possible
as shown in the example below.

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4.2 Options and equipment required

Sensor to be

calibrated

By

simulation

By

bath

By

point

Equipment necessary

Simulator + cable

reference XXX

Bath + extension lead

reference 60525 +

and the sensor to be

calibrated

Life book with

previous values

Sample probe

Possible

Cable ref 60522

Recommended

Possible

Condenser probe

Recommended

Cable ref 60524

Difficult to perform

Possible

Compartment probe

Recommended

Cable ref 60524

Difficult to perform

Possible

Ambient probe

Recommended

Cable ref 60524

Difficult to perform

Possible

TC dry point

Recommended

Cable ref 60523

Difficult to perform

Possible

TC Plate

Recommended

Cable ref 60523

Difficult to perform

Possible

The instrument does not allow storing in memory more than one calibration for fixed probes

(condenser, compartment and ambient probes).

For the sample probe, subject to much handling, it is possible to store as many calibrations as probes
are required. As a result with these previous calibrations, if the sample probe is defective or broken,
it is possible to connect another probe which has been previously calibrated and to select this
calibration to activate it.

4.3 Calibration of sample temperatures

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Enter the name of the probe

and identify the person

creating the calibration.

For each calibration, it is possible to:

- Creation: Create a new calibration (case of a new probe).

- Modification: Modify a calibration (in the event of a deviation or erroneous

measurements).

- Delete: Delete a calibration (if the probe is destroyed or calibration is false).

- Display: See a calibration (allows checking the points entered).

- Default: Declares a probe selected by default (this is the probe called up when starting a

test).

- Printing: Print out the calibration.

For sample probes, it is possible to store 1,000 calibrations. This allows carrying out a
calibration session when the measuring instruments are available and storing the calibrations
under the probe reference number. In operation, if it is necessary to change the probe
(following breakage or deviation in results), simply connect the new probe and declare it in
the instrument.

The display mode allows displaying the current calibration points and reading the value of
the temperature in real time.

4.3.1 Example of creation of a new calibration

In the event of a modification, the previous

fields remain completed and the ‘modified by’
and the ‘modified on’ fields must be

completed before you can move on to the
next sequence.

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Respond yes or no depending on

the bath temperatures available

and values preselected on screen.

Depending on the equipment available, there are two possibilities:

- one or two baths stabilised at temperature are available and it is possible to carry out

calibration with the probe.

- One Pt100 probe simulator (decade resistor or calibrator): the probe will be replaced by

the simulator.

Calibration by bath:

- Disconnect the probe and insert the extension (accessory reference 60525) between the

probe and the instrument so the probe can be immersed in each calibration bath.

- Select the calibration mode (Real).

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The instrument waits for the value read off to

stabilise (value stable at 800 conversion points) and
calculates the average of five acquisitions.

Confirm by selecting the green tick, restart

measuring by selecting ‘restart’ mode or cancel and

exit by selecting the red cross.

NB: to make a calibration with sufficient

accuracy, the system imposes a
difference of 80°C between the two
calibration points.

If preselections are not appropriate, reply ‘yes’

and use the keyboard on screen to enter the
new point values. End each input session with
a green tick.

The procedure requires placing the probe in
the lowest temperature bath (example

50.3°C) and confirming by ‘OK’.

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The procedure displays the calibration

points with the conversion points and
asks for confirmation or otherwise.

If confirmation is accepted, calibration
will be displayed and can be used when
selected by default.

NB: If the signal is too unstable, the instrument will not achieve stability and remains in this function.
It is possible to force it by pressing the green tick (but the calibration will not be accurate given the

instability).

Follow the same procedure for the high
calibration point, place the probe in the warmest
bath and confirm with the green tick.

Calibration with a simulator:

Calibration by simulation with a Pt 100 calibrator (or decade box) is similar to calibration by bath. It
requires the calibration cable reference 60522 to connect the calibrator in place of the probe.

This calibration allows calibrating the acquisition system of the instrument, excluding the
temperature probe. Error introduced by this sensor is not incorporated.

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4.3.2 Commissioning a new sample temperature probe

When commissioning a new sample temperature probe, it is necessary to verify the position of the
ring which detects correct positioning of the probe on the flask.

 Place the centering stopper on the probe and place the whole assembly on the neck of the

flask (1).

 Lower the probe to place the sensitive part of the probe perpendicular to the flask tapping

point (2).

 Lock it in this position by turning the knurled ring of the centering stopper.

 Place the flask with its centering stopper and its probe in the heating block and adjust height

of the probe ring so the detector is in the lower position when the assembly is in the final
position (centering stopper engaged in the flask neck). (3).

4.4 The Pt 100 temperature probes internal to the instrument

The condenser tube, test tube compartment and the ambient temperature probes fall into this
category.

It is not possible to create or delete a calibration for these probes.

The calibration procedure is identical to that for the sample probe (see above).

The probes are integral to the instrument, and calibration can be performed exclusively by
simulation.

NB: The error introduced by the sensor remains acceptable for these temperature measurements.

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4.5 Temperature measurements by thermocouple

These measurements refer to:

- The dry point detection thermocouple

- The heating element temperature measuring thermocouple

The calibration of these sensors can only be performed in simulation mode using the calibration
reference 60523.

The sensor measuring temperature of the heating block is adjacent to the instrument. The
calibration procedure does not allow calibrating several heating block thermocouples
(referred to as the ‘plate probe’).

The procedure offers only modification or display of calibration of the Pt dry point
thermocouple since calibration of this element is not critical: the instrument uses the sensor
to detect the dry point by a temperature variation. The absolute temperature values are thus
not critical.

The procedure is identical to the Pt 100 probe
calibration by simulation (see above), simply
simulate two temperature points (a minimum
of 80 °C apart).

4.6 Calibration of the barometric sensor

Barometric calibration allows modifying the calibration of the barometric sensor. Calibration is
performed by generating two atmospheric pressure values directly on the sensor.

Equipment required:

- One absolute standard reference pressure gauge

- One system allowing generating two pressures above and below atmospheric pressure

- One connection hose

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NB: If it is not possible to carry out
calibration of the barometric sensor
for lack of measuring equipment, it is
possible to set the instrument in
manual configuration to correct the
atmospheric pressure. As a result,
when starting the test, the
instrument will display a screen for
entering the barometric pressure
using the keyboard.

Display mode allows displaying the current calibration points and reading the atmospheric
pressure in real time.

When entering the calibration points, the instrument waits for stabilisation of the
measurement (variation below 0.3 mB) and calculates and average of five consecutive
acquisitions.

In order to perform a calibration which is sufficiently accurate, the two calibration points
must be a minimum of 100 mB apart.

Connection to internal barometric

pressure sensor

Pump generating different pressures

Absolute standard reference pressure
gauge used as the reference

T-junction connecting the sensor of the
instrument under calibration and the
absolute standard reference pressure
gauge to the pump.

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4.7 Calibration of test tubes

In order to measure the exact volume, calibration of test tubes used on the instrument is
recommended.

As for the sample temperature probes, it is possible to store several calibrations (maximum 1000).

The level follower screen proposes:

- Creation: create a new calibration (case of a new test tube)

- Modification: modify a calibration (in the case of a deviation or erroneous

measurements)

- Deletion: delete a calibration (if the test tube is destroyed or the calibration is false)

- Display: display calibration (allows checking the points entered)

- Default: declares a test tube selected by default (it is this test tube that will be called up

when starting a test)

- Print: allows printing out the calibration values

The calibration procedure consists in placing two known precise volumes of liquid in the test tube.

During the procedure, it is possible to modify the two calibration volumes. However, in accordance
with the standard, it is recommended to retain the points 5 mL and 100 mL.

The 5mL point must be calculated precisely (by weighing or pipette). The 100 mL point will
preferably be made using the test tube graduation, since it is the mark that will be used
subsequently during the tests to pour 100 mL into the flask.

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In order to ensure the same type of meniscus during calibration and measuring, it is
recommended carrying out calibration with the same type of liquid as the samples to be
analysed.

Procedure:

Equipment necessary:

- The test tube or test tubes to be calibrated.

- A 5 mL pipette or set of scales (range 200 G, accuracy 0.1 g and knowledge of exact

density).

- 120 mL of liquid similar to the samples.

Do not carry out calibration with water. The meniscus is contrary to that of
hydrocarbons.

Do not use extremely volatile liquids.

4.8 Calibration of the tactile pad

This function allows recalibrating the tactile pad with the screen. A utility is started and you are
requested to point at the points displayed on the screen.

4.9 Monitoring expiry of calibration deadlines

This function is not ticked on delivery of the
instrument.

Meniscus

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Its purpose is to monitor each magnitude to be calibrated in the instrument and expiry of the
calibration period.

It also allows, if the deadline is exceeded, prohibiting starting a test if the option is selected.

To choose this option, select the icon on each screen of a magnitude to be measured (after
completing the field “modified by” and the “modification” function).

If the expiry function is ticked, access is possible to
the frequency and warning message parameters:

Frequency: defines the frequency of validation of
calibration with as the starting point, the date of
calibration.

Warning message: an alarm message displayed X
days prior to expiry of calibration.

If the function “refuse to start test” is activated, it will not be possible to start a test with this

calibration.

5 Denomination and functions of the electronic boards

5.1 Process CPU

Manage acquisitions , regulations and processes

5.2 MMI CPU

Manage orders and peripherals : printer , displays , communication ports ( USB , Serial and Ethernet)

5.3 CL1 board :

- Manage the sensors :
o barometric pressure

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o PT 100 probes
o Thermocouples
o Drip deflector sensor
o Liquid detector of expansion tank
o Door sensor of heating block
o Door sensor of compartment
o Limit switches of level follower
o Optical sensor ( first drop and follower)

- Manage the I/O relay:

o General power supply
o Powering Peltier and stepper motor power supply
o Heating block relay
o Turbine of heating block
o Drive the stepper motor board
o Hot/cold compartment
o Hot/cold condenser
o Main circuit breaker tripping
o Check the main voltage

5.4 CL2 board :

Interconnection board

5.5 CL3 board :

Relay board :

- Main power

- Control for power Peltier, stepper motor and heating block transformer

- Relay circuit breaker tripping

5.6 CL4 board :

Interconnection board for Pt100 and thermocouple calibrations

5.7 CL56F et CL 56C boards :

Interconnection board :

- Between the process and MMi boards

- Between front panel and frame

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5.8 Stepper board:

Drive the stepper motor power

6 Schematic electrical and electronic

6.1 Interconnection scheme

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6.2 Spares part list

6.2.1 Probes and thermocouples

6.2.2 First drop and follower optical sensors

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6.3 Scheme of electronic boards

6.3.1 CL1 board

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6.3.2 CL2 board

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6.3.3 CL3 Board

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6.3.4 CL4 board

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6.3.5 CL56 board

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6.3.6 Stepper motor board

6.3.7 Detector probe and door closed detector sensor

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6.3.8 Front panel

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7 Spares part list

26111

100 mL glass test tube with base

60516

100 mL anti-mist glass test tube with base

60512

Diaphragm

60514

Bag of pumice stone

60513

Condenser cleaning cable

12609EC

5mL graduated cylinder for residue

40065

Centering stopper for 125 mL flask

40064

Centering stopper for 125 mL flask with
passage for dry point thermocouple (for dry
point in D86)

40067

Centering stopper for 200 mL flask

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40081

Grip for centering plug for 200 mL flask

60515

Stopper for connecting condenser tube and
flask

60510

PT 100 sample probe without position ring

60552

Position ring for Pt 100 sample probe

60509

Thermocouple for dry point detection

24019

125 mL flask

19422

200 mL flask

40043

200 mL flask with black base

60511

Drip deflector(packet of 5 parts)

60508

Heating block plate with hole diameter 50 mm

60507

Heating block plate with hole diameter 38 mm

60506

Heating block plate with hole diameter 32 mm

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60505

Heating block plate with hole diameter 25 mm

40040

Kit of 10x 'O' ring seals with centering stopper
for 125 mL flask

40042

Kit of 10 'O' ring seals with centering stopper
for 200 mL

60520

Uninterruptible power supply (UPS)

60521

Ethernet Cable

60532

Serial Cable (RS232)

60522

Sample temperature measuring calibration
cable by simulation

60523

Calibration cable for measuring thermocouple
temperature by simulation

60524

Calibration cable for measuring internal Pt
100 probe by simulation

60525

Extension cable for calibrating the sample
temperature measuring system using a bath

60526

USB key with retrieval system

60527

Bar code reader

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60528

Extinguishing system nitrogen connection
tube

60553

Resistor box to simulate Pt100 probes

60554

1st drop detection fork

60555

Level follower fork

40012

Coolant liquid (2 liter bottle)

60556

CL1interface card

60557

UC IHM card

60546

CL2 card

60547

CL3 card

60548

CL4 card

60549

CL56 card

60558

Kit VOC ( zeolite)

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60559

Electronic cards power supply

60560

Back-light card

60561

Peltier element S/E regulation control card
(compartment or condenser)

60562

Sample probe presence sensor card

60563

Step motor card

60564

Heating block high position sensor card

60550

230 V color inkjet printer

None

60551

115 V color inkjet printer

None

60565

Process CPU

60566

Touch pad driver

60567

flask heating block cooling turbine

60568

Condenser Peltier S/A fan (without filter)

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60569

Compartment Peltier S/A fan (without filters)

60570

Dust filter for fan Peltier S/A

60571

Sensor detection of level in fluid circuit coolant
liquid

60572

Drip deflector detection sensor

60573

Compartment door closed detection sensor

60574

Sensor detecting follower high or low position

60575

Pt 100 probe - condenser temperature

60576

PT 100 probe - test tube compartment
temperature

60577

flask heating block thermocouple

60578

Heating block detection thermocouple

60579

Level follower step motor

60580

Low test tube retention system

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60581

High test tube retention system with detection
of flow finger

60582

12 V DC relay

60583

230 V AC relay

60584

24 V DC relay

60585

125 V AC relay

60586

Main circuit breaker

60587

800 VA 25 V transformer

60588

Heating block heating static relay

60589

Static relay heat sink

60590

Heating circuit fuse 40A 14X51 mm (box of 10
fuses)

60591

Fuse holder for heating block heating circuit

60592

Touch pad

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60593

LCD color screen

60594

Condenser temperature regulation sub­assembly

60595

Test tube compartment temperature
regulation sub-assembly

60596

Peltier element S/A power supply
(compartment or condenser)

60597

Hard disk with Windows license

60598

Mains on/off switch

60599

Insulated full condenser tube assembly

60600

Glass door of heating bloc

60601

Condensate drawer compartment

60602

Collection drawer of heating block

60603

Coupling for step motor

60604

Centering roller for flask in heating block

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60605

Latch for locking heating block door

60606

Circulation pump for coolant circuit

60607

Coolant circuit drain valve

60608

Receiver compartment door hinge with spring
(pair)

60609

Latch for locking test tube compartment door

60610

Receiver compartment door

60611

1st drip fork or follower spring

60612

Magnet for follower position detect

60613

Magnet for test tube compartment door

60540

flask heating element sub-assembly with
thermocouple

60615

Fluid circuit expansion chamber

60616

Head sink thermostat

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60617

Translator for test tube compartment follower

60529

4 port 2.0 USB hub

60530

Nitrogen electro valve kit for test tube
compartment

none

60531

Extinguishing system nitrogen bottle

60618

30 A 230 V power relay

60619

30 A 115 V power relay

60620

Set of 2 power switches contacts (male and
female) for heating block heating element

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8 Troubles shooting

Degraded

function

Description

Solution or check to perform

General

The circuit breaker does
not remain engaged.

Verify that the mains voltage is in
concordance with that displayed on the
instrument.

The circuit breaker is
tripped when a test is
started.

Check that the transformer of the flask
heating circuit.

Switchover the switch on the two internal
power supplies and verify whether the
problem persists.

The fuse of the heating
block heating element
has blown.

Verify that the heating element circuit is not
damaged.

Problems on

results

The results are

divergent in

temperature

Verify that the sample temperature probe is
correctly displayed and calibrated.

Verify that calibration of the test tube and its
declaration.

Verify that calibration of the barometric
sensor.

Verify that the final volume.

Verify that leak tightness of the stopper
connection between the flask and condenser
tube.

Initial boiling point is

divergent

Verify that temperature conditioning of the
sample on starting the test.

Verify that the position of the probe in the
flask neck (see standard).

The test does not

Problem of adjustment

Verify that the power leads for the internal

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start or takes a

long time to start

of compartment or

condenser temperature

power supplies are correctly positioned.

Verify that the switch for each internal
power supply is at ‘on’.

Verify that the fan filters are not clogged by
dust.

Verify that the temperature exchanges of
the compartment or condenser sub­assemblies are not clogged by dust.

Verify that the fans can rotate freely.

Verify the ambient temperature in the
laboratory and of the instrument (proximity
to an instrument emitting hot air).

Verify the level of liquid in the expansion
chamber of the condenser circuit.

Verify that the condenser circuit circulation
pump is operating.

The heating element of

the heating block does

not heat up, or heats up

only slightly

Verify the heating circuit fuse.

Verify the heating thresholds in the product
file.

Verify the calibration of the heating block
thermocouple.

Flow rate

incorrect or

unstable

Poor regulation of flow

rate

Check that the drip deflector is correctly
positioned (it must touch the glass wall on
the front).

Place glass balls or pumice stone in the flask
to attenuate disturbance during boiling.

Verify the values in the product file.

Verify that the sample does not swell up
because of a not adapted product file or
presence of water in the sample.

Verify that the instrument is stable and

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exempt from vibration (which can generate
surface waves on the liquid and interfere
with the follower).

Verify the calibration of the plate
thermocouple.

Verify the mechanical position of the plate
thermocouple.

Flow rate value not

correct.

Product file ill-adapted.

Poor choice of standard.

Heating block plate ill-adapted.

Level follower

The follower rises

without any liquid in the

test tube

Check the for presence of mist on test tube.

Check the cleanliness of test tube and optical
sensor (emitter and receiver).

The follower does not

follow the liquid.

Verify the positioning of the follower cell in
relation to the test tube.

Detection of initial

point (IBP)

The instrument does

not detect the initial

point (IBP)

Verify alignment of the cell with the
perpendicular of the end of the condenser
tube.

Verify absence of mist or other particles
perpendicular to the optical detector.

Poor initial boiling point

value (IBP)

The condenser was not cleaned before the
test.

Condenser temperature ill-adapted for
sample (risk of fixing in the condenser).

Dry Point

Detection

No detection or
divergent value

Verify the sensitivity displayed.

Verify the dry point was requested in the
product file.

Verify the dry point actually exists (too much
residue).

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Final boiling point

detection (FBP)

No detection or

divergent value

Verify that the modification of final heating
is not too great in relation to the declared
detection threshold.

Verify declared protection threshold.

Final volume

The final volume is not

correct

Verify the calibration of the test tube and its
declaration.

Ensure that the initial volume was correct.

Verify that the temperature of the test tube
compartment is correct (an increase in the
temperature expands the liquid and falsifies
measurement of the volume or evaporates
light distillate samples).

Verify the final residue.

Verify the leak tightness of the connection
stopper between the flask and silicone tube.

Verify the presence and efficacy of the
diaphragm on the test tube neck (case of
light distillate products).

The test tube has been cleaned and dried
before charging in the flask (error on drips
remaining in the test tube).

Poor calibration with a liquid generating a
convex meniscus (verify with level detector
on the sample).

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9 Annexe 1

9.1 Guide to update instrument

9.2 Safety rules

NORMALAB NDI 450 distillation unit is a high quality instrument. The recommendations and
instructions in this document will allow you to update your instrument. Make sure you read and
understand this guide. Keep it close to the instrument so you can consult it easily.

9.3 General characteristics

The distillation unit is offering two microprocessor cards. One computer board under Windows XP
Embedded operating system for Man Machine Interaction (MMI software). And other computer
board under Free-Dos operating system for instrument process (For convenience, we call this
software "firmware"). To ensure this equipment provides the reliable prolonged service for which it
was designed, we emphasize the importance of updating or upgrading the MMI software and the
firmware on regular bases.

9.4 Content of new version

A new version includes adjustments, new improvements to features and services in NDI450 software.
This update replaces your current version of NDI450 software, and keeps your files and settings in
place in your instrument. You can check the new adjustments and features here:

http://www.normalab.com/software/NDI450/NDI450 What's new.pdf

9.5 How to get a new version

The recommended (and easiest) way to get NDI450 new software is to download on Normalab
Website. Download and save the appropriate files for your instrument from the Normalab NDI450
Download Center: http://www.normalab.com/software/NDI450/Software/Update.zip

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9.6 How to know the software version

The MMI ID software version is visible in the toolbar on the main screen.

The firmware version is visible in the “Command shell“page with the command “ver”.

9.7 Important recommendations

- Make a new backup of MMI software before starting an update.

- Please always check the software or firmware version before starting an update.

- Never update your instrument with a previous version than the installed one.

- Be sure your new version is compatible with your instrument. Please contact us for

confirmation.

An incorrect installation can involve a dysfunction of the unit, company NORMALAB France SAS

could not be responsible for incorrect installation of software or firmware done by your side on

this equipment.

9.8 Additional requirements to update your NDI450 instrument

- 1 Computer with Internet access (fees may apply).

- 1 USB flash/pen/key/stick drive (Don’t use the USB flash drive supplied with your

instrument).

- 1 Ethernet cable for update the firmware (It’s supplied with your instrument).

9.9 Prepare your USB flash drive for updating (video example)

- Plug-in the USB flash drive to computer

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- Open the drive letter assigned to the USB flash drive by looking at the list of drives in window

explorer.

- Create a new folder named “Update” (if not exist).

- Extract and copy the NDI450 new version into the Update folder.

The file named “MMI_X_XX.NDI” is the update version for the MMI software. The version number of
the new software is “X_XX”.

The file named “FIR_Y_YY.NDI” is the update version for the firmware. The version number of the new
firmware is “Y_YY”.

- Unplug the USB flash drive from the computer.

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9.10 Install a new MMI version using the Update option (video example)

- After NDI450 software has started, check the version of the MMI software before starting an

update.

- Plug-in the USB flash drive to your instrument. Software should detect automatically your

USB flash drive.

- On the “Software setup” page, click “Software update”.

- On the “Software update” page, click “Load the updates list”.